FERS PHENOLIC RESINS FOR ABRASIVES MANUFACTURING

Toni Oller BU Technical Resins Director FERS Resins S.A.U. (Sumitomo Bakelite Group)

F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005

FERS Resins - M i l e s t o n e s
Sumitomo Bakelite Group ISO9001:2000 ISO14001:1996 2000 2003 2004 2005

Programm:
1944 1949 1953

15 Technical Papers
1960 1977 1996 1999

100%Change to New Plant Montorns 50th Anniversary ISO9002:1994 New Land in Montorns Beginning Export Sales Years of Consolidation Foundation by Oller Brothers. Brothers Joaquim and Eugenio Oller started trials with phenolic resins

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European manufacturing & Sales network Phenolic Resins

SUMITOMO BAKELITE Europe n.v. DUREZ Div. Genk Belgium

SUMITOMO BAKELITE EUROPE (Belgium Genk) ISO9001/2000 ISO14001/1996

Durez division

FERS RESINS (Montorns Spain) ISO9001/2000 ISO14001/1996

l

Production (Resin) : 2 countries

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Global manufacturing & Sales network Phenolic Resins

FERS RESINS SUMITOMO BAKELITE EUROPE DUREZ CANADA

Canada Europe SB Japan U.S.A DUREZ CORP

Indonesia

IPJ Production (Resin): 6 countries

F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005

FERS PHENOLIC RESINS FOR ABRASIVES MANUFACTURING

F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005

ABRASIVES MATERIALS

INDUSTRIAL APPLICATIONS

BONDED ( Cut-off and Grinding Wheels, Stones, Segments... )

COATED ( Flexible, semi-Flexible)

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BONDED ABRASIVES

- GRINDING WHEELS - CUTT-OFF & DEPRESSED CENTER WHEELS

TYPE OF BOND: VITRIFIED (Ceramic)) RESINOID RUBBER METALLIC (Superabrasives)

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BONDED ABRASIVES
Typical Formulation ( in weight )
ABRASIVE ABRASIVE 76

BONDS

POWDER RESIN

12

Usual Ration LR/PR is 1:4 to 1:2

LIQUID RESIN

FLUORITE, ...

Relation PR + Filler / LR from 3.5 to 7

PYROX, ...

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BONDED ABRASIVES
PF Bond formulation: Typical resin characteristics and ranges:
PF Powder Novolac Typ.Parameter Flow, mm Hexamine, % Sm (cm2/gr) Typical ranges Short: 12-20 / Medium: 21-35 / Large: 35-70 Low: 4-6 / Medium: 7-9 / High: 10-14 Low: 4000-5000 / Medium: 5000-7000 / High: 7000-9000

PF Liquid resin Typ.Parameter Typical ranges Solid Cont. % Viscosity, cps Free Phenol Low: 65-70 / Medium: 70-75 / High: 75-80 Low: 300-1000 / Medium: 1000-2000 / HIgh: 2000-4000 Low: <2 / Medium: 2-10 / High: 10-20

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Powder Resin type

Flow

Liquid Resin type

Particle size

Gel time

Curing Time

BONDED ABRASIVES: RESIN GRADE SELECTION FACTORS

Mw

Viscosity

Free Phenol Solvent type

Others

Others

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BONDED ABRASIVES: RESIN GRADE SELECTION FACTORS

APPLICATION

3 2 1 0
ENVIRONMENT
RESIN GRADE

MANUF.PROCESS

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BONDED ABRASIVES
MANUFACTURING PROCESS

GRINDING WHEEL MANUFACTURE: 1. Mixing 2. Moulding 3. Curing (Oven or Kiln) 4. Finishing 5. Testing

Abrasive Liq Res

Bond: Res Pol +Filler

Mixing

Moulding

Curing

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BONDED ABRASIVES
MANUFACTURING PROCESS

Processing variables
Mixing / Different technologies / Mixing room conditions Pressing / Different technologies and Systems / room conditions Curing / Standard and Fast Curing Cycles / Oven technology. Final Properties / Aging , Optimizing Performance, etc

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BONDED ABRASIVES: RESIN GRADE SELECTION FACTORS

APPLICATION

MATERIALS Non Fe Metals & Alloys Fe Metals & Foundry Stainless Steel Ceramic & Stone

MACHINES Non-Precision Machines Precision Machines Variety of Bonded Abrasives

ENVIRONMENT Environment Regulations Safety Regulations Market Behavior

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BONDED GRADE SELECTION FACTORS BONDED ABRASIVES: RESINABRASIVES

APPLICATION / GUIDELINES FOR BONDED ABRASIVES VS MATERIALS BEHAVIOR
Non-Fe Metals+Alloys
5 4 3 2 1 0

Ceramics

Steel+Cast Iron

Stainless Steel

Tens.Strength Impact Heat

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BONDED ABRASIVES

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TYPE OF RESINOID ABRASIVE / APPLICATION NONPRECISION MACHINES ROUGH SNAGGING-SNAGGING

REMARKS

RESIN CRITERIA

HIGH REMOVAL. HIGH PRESSURE THOUGHNESS. HIGH HARDNESS. REINFORCED GENERAL PURPOSE GRINDING WHEELS AND DEPRESSED CENTER WHEELS (#27). POWDER RESIN: FLOW MEDIUM/SHORT. HEXA MEDIUM/HIGH. OPTION EPOXY MOD. EX: FB8107, FB8001, FB8001/2, F910 LIQUID RESIN: STANDARD GRADES. EX: F508, F511, F504B POWDER RESIN: SHORT FLOW. HIGH HEXA. EX: FB8023, F1021P / WETTING AGENT: STAB/AF (FURF.ALC.) POWDER RESINS: FLOW MEDIUM/SHORT. HEXA MEDIUM. OPTION EPOXI AND PVB MOD. EX: FB8001/2, F1021P, F910, FB8709 LIQUID RESIN: ALCALI FREE (LR) F504B, F504

(COLD PRESSING)

(HOT PRESSING)

SNAGGERS AND SEVERE ROUGH GRINDING IN STEEL MILLS AND FOUNDRIES.

CUTTING OFF WHEELS (COLD PRESSING)

HIGH PRESSURE. THOUGNESS AND HARDNESS. REINFORCED. EX: THIN WHEELS.

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BONDED ABRASIVES

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TYPE OF RESINOID ABRASIVE / APPLICATION PRECISION MACHINES EXTERNAL GRINDING

REMARKS

RESIN CRITERIA

FINE ABRASIVE GRIT. MEDIUM DENSITIES. COOLANT RESISTANCE.

POWDER RESIN: FLOW MEDIUM-LONG. HEXA MEDIUM/LOW. OPTION EPOXY MOD, PVB MOD. EX: FB8001, FBF1006P, F910, FB8709 LIQUID RESIN: ALCALI FREE. EX: F504B, F501 POWDER RESIN: FLOW LARGE. HEXA MEDIUM-LOW. OPTION RUBBER MOD, EPOXY MOD. EX: FB8001, F1400P, F910 LIQUID RESIN: ALCALI FREE. EX: F504B, F501 POWDER RESIN: FLOW MEDIUM-LARGE. HEXA MEDIUM. OPTION EPOXI AND RUBBER MOD. EX: FB8001, F910, F1400P LIQUID RESIN: ALCALI FREE. EX: F504B, F501 POWDER RESIN: FLOW MEDIUM-LARGE.. HEXA LOW. EX: FB8018, F1006P. LIQUID RESIN: ALCALI FREE. EX: F504B, F501 POWDER RESIN: FLOW SHORT, HIGH HEXA. EX: FB8023, F1021P WETTING AGENT: STAB/AF.

EXTERNAL GRINDING LARGE DIAMETERS ROLL GRINDING.

FINE ABRASIVE GRIT. MEDIUM-LOW DENSITIES. COOLANT RESISTANCE

CENTERLESS GRINDING

SNAGGERS AND SEVERE ROUGH GRINDING IN STEEL MILLS AND FOUNDRIES.

SURFACE GRINDING FACE

CYLINDER / NUT INSERTED DISC WHEELS. SEGMENTS. FINE/MEDIUM SIZE ABRASIVE GRIT. MEDIUM/LOW DENSITIES. COOLANT RESISTANCE.

BONDED SUPERABRASIVES DIAMONT WHEELS

APPLICATIONS IN GLASS, CERAMIC AND STONE.

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POWDERED RESINS FERS Code Unmodified F1006P F1009P F1010P F1012P F1021P F1026P F1050P FB8001 FB8001/2 FB8018 FB8020 FB8023 FB8050 FB8107 FB8108 FB8309

General purpose Wheels

High Density Wheels

Hot pressed Wheels

Though Wheels

Coolant resistant Wheels

Diamond Wheels

X X X X X X X X X X X X X

X X X X

X X X X

X X X X X X

X X

X X

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POWDERED RESINS FERS Code Modified F910 (epoxy)

General purpose Wheels

High Density Wheels

Hot pressed Wheels

Though Wheels

Coolant resistant Wheels

Diamond Wheels

X X X X X X X X

X X X X X X X X

F9003 (epoxy) F9105 (epoxy) F1400P (rubber) F1420P (rubber) FB8709 (PVB) FB4504 (Chromite)

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LIQUID RESINS Alkali liquid resins Alcali Free liquid resins

REMARKS PF Resols water based (solvent free) , HighMedium Free Phenol%, Good wetting properties and high digestion for powder resins. PF Resols water or solved based, Low-Medium Free Phenol%, Storage stable mixes for authomatic presses, PF Novolacs solved based with low free monomers (Phenol and Formaldehyde). Storage stable mixes. Long shelf life resins.

SUGGESTED APPLICATIONS Snagging and General Purpose dry grinding. Coolant resistant wheels, Cutting-Off and DC wheels, General purpose for free and wet grinding. Snagging and General purpose dry and wet grinding.

RESIN GRADES F508, F511, F512, F514 F504B, F501, F504, F506K

SN liquid resin

F5250L, F5251L, F5252L

Temperature - Viscosity Graph 7.000 Viscosity cps 6.000 5.000 4.000 3.000 2.000 1.000 0 15C 20C 25C 30C Temperature C 35 40C
F501 F512 F520

LIQUID RESINS FERS Code F501 F504B

Shelf life at 20C 2 1

Shelf life at 10C 6 3

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LIQUID RESINS

EFFECTS ON DIFFERENT SOLVENTS

FREE PHENOL

-Dissolves Novolac, Hexa and Resol. -Effective Wetting agent. -Less reactive than FA at low temperature. -Dissolves slowly Novolac due to difficulties to penetrate particles. -Longer time is needed before mix is useful. -Gives additional flow at low temperature. -Gives longer stability to the mixture. -Does not dissolve Novolac, but hexa and behavior with resole depends on the water- tolerance. -Gives relatively high viscosity at low temperatures (<70C). -Non-reactive, no function for final wheel. -Helps penetration of Resol to the Novolac particles, and mixture can be used shortly. -Mixture is sensitive to room climate (moisture).

FURFURYL ALCOHOL

WATER

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BONDED ABRASIVES
ENVIRONMENT FACTORS

Environment Regulations

Market Behavior

Safety Regulations

F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005

ABRASIVES MATERIALS

INDUSTRIAL APPLICATIONS

BONDED ( Cut-off and Grinding Wheels, Stones, Segments... )

COATED ( Flexible, semi-Flexible)

F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005

ABRASIVES MATERIALS A basic approach to the Fiber discs Manufacture Process 0,8 & 2 mm Vulcanized Fiber thickness Cutting Print 1st Layer ( Maker ) Resin + Abrasive

(number of passes & speed, to be adjusted to the desired product weight) 2nd Layer ( Sizer ) Resin Packing & Form Drying Oven aprx. 2 h at 80 C

Curing Oven 70 130 C ; 24 to 48 h

Humidification Chamber ( 65 75 % HR ) Flexing Packaging

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COATED ABRASIVES: FIBER DISCS

ABRASIVE ABRASIVE REMARKS

BACKING

FIBER BACKING

0,6 up to 2,3 mm

BOND LAYER

LIQUID RESIN

60-70%

FERS RESIN GRADES: TH5, TH14. Additional solvent up to 0,5% to adjust viscosity.

FILLERS

30-40%

Cryolite, CaCO3, etc

PF Liquid resin Typ.Parameter Solid Cont. % Viscosity 25c, cps Gel Time 100C Free Phenol % Typical ranges Low: 65-70 / Medium: 70-75 / High: 75-80 Medium: 1500 / HIgh: 3000 50 70 min Low <3 / Medium 8

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ABRASIVES MATERIALS A basic approach to the Roll Coating Manufacture Process Maker 1 Bond layer Coating ( abrasive layer ) Drying (65nd 70C) Sizer 2 Bond layer Drying-Curing (115-125C) Conditioning Jumbos (Controlled Moisture & temp storage) Finishings ( Belts, sheets, discs.., Flexing...)
st

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COATED ABRASIVES: BELTS AND SHEETS

ABRASIVE BACKING BOND LAYER 1) MAKER 2) SIZER ABRASIVE FIBER BACKING LIQUID RESIN 50-60% Usual materials: special Kraft papers, woven cotton, etc Backing material available up to 2 m wide. FERS RESIN GRADES: TH250, TH3478/2, TH751/500, TH751M, DUREZ33104. Additional solvent up to 0,5% to adjust viscosity.

FILLERS

40-50%

Cryolite, CaCO3, Others.

PF Liquid resin Typ.Parameter Solid Cont. % Viscosity 25c, cps Free Phenol Typical ranges 70 / 80 Maker: 1500-3500 / Sizer: 500-2500 Low 3 / Medium 8

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COATED ABRASIVES: BELTS AND SHEETS

POWDERED RESINS FERS Code Modified TH215 TH252/500 TH751/500 TH3478/2 TH751BM DUREZ33104 X X X X X X X
General purpose Wheels Flexibility Water resistant

Resin Targets: -To reduce free monomers (P, F) -To stabilize colour.

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FERS PHENOLIC RESINS FOR ABRASIVES MANUFACTURING

Our Technical Challenges: To support our Customers offering resins:

More reliable with the Environment Better Performance Easy Processability Available for any Process At reasonable Cost

F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005

FERS RESINS : YOUR PF RESINS PARTNER FOR THE ABRASIVES MARKET

ISO14001

ISO9001

F E R S S U M I T O M O A B R A S I V E S C O LL O Q U I U M 2005